WO2023003008A1 - 熱応動素子及びその製造方法 - Google Patents
熱応動素子及びその製造方法 Download PDFInfo
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- WO2023003008A1 WO2023003008A1 PCT/JP2022/028148 JP2022028148W WO2023003008A1 WO 2023003008 A1 WO2023003008 A1 WO 2023003008A1 JP 2022028148 W JP2022028148 W JP 2022028148W WO 2023003008 A1 WO2023003008 A1 WO 2023003008A1
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- responsive element
- shape
- thermally responsive
- bimetal
- temperature
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H37/00—Thermally-actuated switches
- H01H37/02—Details
- H01H37/32—Thermally-sensitive members
- H01H37/52—Thermally-sensitive members actuated due to deflection of bimetallic element
- H01H37/54—Thermally-sensitive members actuated due to deflection of bimetallic element wherein the bimetallic element is inherently snap acting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/10—Stamping using yieldable or resilient pads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/08—Dies with different parts for several steps in a process
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K5/00—Measuring temperature based on the expansion or contraction of a material
- G01K5/48—Measuring temperature based on the expansion or contraction of a material the material being a solid
- G01K5/56—Measuring temperature based on the expansion or contraction of a material the material being a solid constrained so that expansion or contraction causes a deformation of the solid
- G01K5/62—Measuring temperature based on the expansion or contraction of a material the material being a solid constrained so that expansion or contraction causes a deformation of the solid the solid body being formed of compounded strips or plates, e.g. bimetallic strip
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K5/00—Measuring temperature based on the expansion or contraction of a material
- G01K5/48—Measuring temperature based on the expansion or contraction of a material the material being a solid
- G01K5/56—Measuring temperature based on the expansion or contraction of a material the material being a solid constrained so that expansion or contraction causes a deformation of the solid
- G01K5/62—Measuring temperature based on the expansion or contraction of a material the material being a solid constrained so that expansion or contraction causes a deformation of the solid the solid body being formed of compounded strips or plates, e.g. bimetallic strip
- G01K5/64—Details of the compounds system
- G01K5/68—Shape of the system
-
- G—PHYSICS
- G12—INSTRUMENT DETAILS
- G12B—CONSTRUCTIONAL DETAILS OF INSTRUMENTS, OR COMPARABLE DETAILS OF OTHER APPARATUS, NOT OTHERWISE PROVIDED FOR
- G12B1/00—Sensitive elements capable of producing movement or displacement for purposes not limited to measurement; Associated transmission mechanisms therefor
- G12B1/02—Compound strips or plates, e.g. bimetallic
Definitions
- the present invention relates to a thermally responsive element used for a temperature switch such as a thermostat and a manufacturing method thereof.
- Defrost heaters installed in refrigerators and equipment used in cold regions, or anti-freezing heaters installed in water pipes and chemical plant manufacturing equipment use temperature switches such as thermostats to prevent overheating and control temperature. is used.
- a temperature switch is used that starts energizing a heater at 3.degree. C. and stops energizing it at 10.degree.
- a temperature switch capable of controlling the temperature of a freezer between -30.degree. C. and -20.degree. C.
- a temperature switch capable of controlling the temperature of a heater between 90.degree. C. and 100.degree.
- Patent Document 1 describes that the reversal temperature and the return temperature can be arbitrarily adjusted, and that it is possible to manufacture a bimetal with a temperature range of about -30°C to 200°C.
- Patent Literature 2 describes a bimetal disk with a small temperature difference (differential) between reversal and re-reversal. This bimetal disk is formed by bending a flat bimetal disk over the entire circumference at a fixed distance from the center so that the cross-sectional shape is straight in both the central part and the peripheral part, and is formed in the shape of a dish with a rim. It is said that it can operate at a temperature lower than room temperature by bending it to the low expansion side.
- Patent Literature 3 describes a disk-shaped bimetal characterized in that at least one surface of the overhanging region is provided with unevenness to increase the surface area. This disk-shaped bimetal is said to have a low reversion temperature and a small temperature difference between them.
- Patent Document 1 merely describes a spherical shape and does not show a specific method for setting arbitrary temperatures in various temperature ranges.
- Patent Document 2 states that a bimetal can be made to operate at a temperature lower than room temperature, but does not describe a detailed method or a specific operating temperature. Furthermore, processing of the uneven surface in Patent Document 3 is considered to be complicated.
- thermoly responsive element that has a high degree of freedom in differential setting over a wide temperature range from a low temperature range below room temperature to a high temperature range above 100° C., and that is capable of setting a relatively small differential.
- a plate-shaped thermal responsive element whose shape changes with changes in temperature, wherein a cross section of the thermal responsive element at room temperature is a composite curved line formed by combining a plurality of curved lines, and the thermal responsive element
- the cross-sections of the central portion and the peripheral portion surrounding the central portion have different curved shapes.
- thermoly responsive element that has a high degree of freedom in differential setting over a wide temperature range from a low temperature range below room temperature to a high temperature range above 100° C., and that can also be set to a relatively small differential.
- FIG. 1 is a plan view of a thermally responsive element according to a first embodiment
- FIG. 2 is a cross-sectional view taken along line A-A' of FIG. 1
- FIG. FIG. 4 is a cross-sectional view of the thermally responsive element after reversing
- It is an explanatory view showing the 1st process of the manufacturing method of a thermally responsive element.
- FIG. 10 is an explanatory diagram showing a second step of the manufacturing process of the thermally responsive element; It is an explanatory view showing the first step of another method of manufacturing a thermally responsive element.
- FIG. 8 is a plan view of a thermally responsive element according to a second embodiment
- FIG. 9 is a cross-sectional view taken along the line B-B' of FIG. 8
- FIG. 4 is a cross-sectional view of the thermally responsive element after reversing
- It is an explanatory view showing the 1st process of the manufacturing method of a thermally responsive element.
- FIG. 10 is an explanatory diagram showing a second step of the manufacturing process of the thermally responsive element; It is an explanatory view showing the first step of another method of manufacturing a thermally responsive element. It is explanatory drawing which shows the 2nd process of another manufacturing method of a thermally-responsive element.
- the present invention will be described below based on the illustrated embodiments. However, the present invention is not limited by the embodiments described below. Also, the dimensional ratios of the shapes shown in the drawings may not be the actual dimensional ratios. Dimensional ratios may be changed in order to explain the shape in an easy-to-understand manner.
- room temperature means a temperature of 18°C or higher and 38°C or lower.
- FIG. 1 is a plan view of a bimetal 100, which is a thermally responsive element according to this embodiment.
- FIG. 2 is a cross-sectional view taken along line AA' of FIG. Both figures show the shape at room temperature of the bimetal 100 formed by multiple stages of pressing using a punch and a die.
- the bimetal 100 is a plate-like member and has a low expansion layer 111 and a high expansion layer 112 located below the low expansion layer.
- the material of the high expansion layer 112 has a higher coefficient of thermal expansion than the material of the low expansion layer 111 .
- the bimetal 100 also has a central portion 121 , an outer peripheral portion 122 surrounding the central portion, and a boundary 123 between the central portion 121 and the outer peripheral portion 122 .
- the bimetal 100 has a concave shape with a center portion 121 recessed when viewed from above, and a convex shape with a center portion 121 protruding when viewed from below. It can also be said that the bimetal 100 is shaped like a rimmed dish.
- An angle ⁇ 1 formed between the central portion 121 and the outer peripheral portion 122 is an obtuse angle.
- the cross-sectional structure of the bimetal 100 is a composite curved line formed by combining a plurality of curved lines.
- the cross-sectional structure of the center portion 121 is curved upwardly, and the cross-sectional structure of both outer peripheral portions 122 on both sides of the center portion 121 is also curved upwardly.
- the radii of curvature of the respective curves may be the same or different in the central portion 121 and both outer peripheral portions 122 .
- the central portion 121 is circular, and the outer peripheral portion 122 is a square with rounded corners.
- the boundary 123 is on the circumference of concentric circles having a diameter length L12 that is 1% to 50% of the diameter length L11 of the circumscribed circle 131 that circumscribes the outer peripheral portion 122 .
- the length L12 of the diameter of this concentric circle is smaller than the width of the rounded square.
- a Ni-Fe alloy can be used for the low expansion layer 111
- a Cu-Ni-Mn alloy can be used for the high expansion layer 112.
- the length, width, corner shape, and plate thickness of the rounded square are arbitrarily set according to the target inversion temperature.
- the bimetal 100 after inversion has a convex shape in which the center portion 121 protrudes, and when viewed from below, it has a concave shape in which the center portion 121 is recessed.
- the shape after inversion is a composite curve formed by combining multiple curves.
- a boundary 123 between the central portion 121 and the outer peripheral portion 122 does not change before and after the inversion.
- the cross-sectional structure of the center portion 121 is curved upwardly, and the cross-sectional structure of both outer peripheral portions 122 on both sides of the center portion 121 is also curved upwardly.
- the radius of curvature of each curve may be the same or different.
- the angle ⁇ 1 formed by the central portion 121 and the outer peripheral portion 122 is an obtuse angle larger than the angle ⁇ 1.
- the angle ⁇ 1 is larger than the angle ⁇ 1, and the central portion 121 and both outer peripheral portions 122 are each curved upwardly, which is the same before and after the reversal. is also possible. Furthermore, as shown in FIG. 2, since the central portion 121 and both outer peripheral portions 122 are curved in the same direction (inward) (upwardly convex curved shape), an extremely low recovery temperature can be set. It becomes possible. Then, when the temperature of the bimetal rises to a predetermined temperature (operating temperature) lower than room temperature, the bimetal reverses by snap action and returns from the shape shown in FIG. 3 to the shape shown in FIG. This operating temperature is a temperature higher than the recovery temperature.
- a predetermined temperature operating temperature
- FIG. 2 has been described as the shape at room temperature after being formed by a plurality of stages of press working using a punch and a die.
- bimetals that have been formed by pressing and then heat-treated have similar characteristics with respect to their shape at room temperature.
- the method of manufacturing the bimetal 100 includes the steps of cutting a bimetal material composed of two metal layers with different coefficients of thermal expansion into an arbitrary shape, and pressing the bimetal material after cutting in multiple stages using a press machine. and forming into bimetal 100 by.
- the multiple stages of pressing are performed in a state in which the bimetal material, the punch, and the die including the die are maintained at a temperature approximately equal to room temperature (18° C. or higher and 38° C. or lower). However, they may be cooled or heated and then pressed in multiple stages.
- the punch is made of metal, such as alloy tool steel, and the die is made of elastic material.
- FIG. 4A shows the first step of pressing the bimetal material 100a after cutting.
- the bimetal material 100a after cutting is placed on a die D having a flat surface.
- the bimetal material 100a is arranged so that the low expansion layer 111 is on the metal punch P1 side and the high expansion layer 112 is on the die D side.
- the punch P1 having a convex curved end surface is lowered to press the bimetal material 100a.
- a bimetal material 100b (FIG. 4B) is obtained by such a first step.
- FIG. 4B shows the second step (final pressing step) of further pressing the bimetal material 100b formed in the first step.
- the bimetallic material 100b obtained by the first step is arranged on a die D having a flat surface. At this time, the bimetal material 100b is arranged so that the low expansion layer 111 is on the metal punch P2 side and the high expansion layer 112 is on the die D side. Then, the punch P2 having a protrusion formed on the end face is lowered to press the bimetal material 100b. By such a second step, the bimetal 100 shown in FIGS. 1 and 2 is obtained.
- the first step when the cut bimetal material 100a is placed on the die D, the high expansion layer 112 is placed on the punch P1 side and the low expansion layer 111 is placed on the die D side.
- This first step yields the bimetallic material 100c (FIG. 5B).
- the second step shown in FIG. 5B similarly to FIG. 4B, the bimetal material 100c is placed so that the low expansion layer 111 is on the punch P2 side and the high expansion layer 112 is on the die D side, and pressing is performed. .
- a substantially cylindrical projection X is formed at substantially the center of the end face Y of the substantially cylindrical punch P2.
- the length L13 of the diameter of the projecting portion X is 1% to 50% of the length L11 of the diameter of the circumscribed circle 131 that circumscribes the rounded quadrilateral.
- a protrusion amount H of the protrusion X from the end surface Y is 0.05 to 1 mm.
- the end face of the projecting portion X and the end face Y therearound may be flat or dish-shaped (recessed). However, it is preferable that the length L14 of the diameter of the end surface Y is equal to or longer than the length L11 of the diameter of the circumscribed circle 131 .
- the end surface Y is not limited to a circular shape, and may be elliptical or rectangular (not shown).
- the effect of the second step (final pressing step) using the punch P2 and the die D made of an elastic material will be described with reference to FIG.
- the bimetal material 100b (or bimetal material 100c) that has undergone the first step is placed on the die D, and the punch P2 is lowered. fixed. When pressed by the punch P2, it is pushed back from the die D made of an elastic material, and the above-described composite curvilinear cross-sectional shape is produced.
- the periphery of the boundary 123 is given a high workability that cannot be obtained by simply pressing with a punch having a curved surface. This makes it possible to set an extremely low or extremely high operating temperature recovery temperature and a relatively small differential of around 10 degrees.
- the present invention is not limited to this.
- the bimetallic material may be press-processed by sandwiching it between upper and lower metal dies having curved shapes matching the curved shape of the target bimetal. After pressing, the bimetal material is subjected to heat treatment at a temperature of 50° C. to 300° C. for, for example, one hour.
- the bimetal material composition, plate thickness, temperature
- the shape after cutting the pressing force (force, time, temperature) in the first step and the second step
- the punch P1 The end face shape, the end face shape of the punch P2 (diameter lengths L13 and L14, protrusion amount H), and the material of the die are each appropriately selected.
- the operating temperature lower than the room temperature
- the return temperature can be set freely.
- the operating temperature, return temperature, and differential can also be adjusted by changing the shape of the end face of the punch P1 in the first step.
- the differential adjustment effect is small, and if it exceeds 50% of the length L11 of the diameter, the bimetal snaps. It is difficult to flip by action, and even if it is flipped, the height after flipping is considered to be low. In other words, it is considered unfavorable for use in temperature switches and the like (cannot be effectively used for opening and closing electrical contacts).
- FIG. 8 is a plan view of a bimetal 200, which is a thermally responsive element according to this embodiment.
- 9 is a cross-sectional view taken along the line BB' of FIG. 8.
- Both figures show the shape at room temperature of the bimetal 200 formed by multiple stages of pressing using a punch and a die.
- the bimetal 200 is a plate-like member and has a low expansion layer 211 and a high expansion layer 212 located below the low expansion layer.
- the material of the high expansion layer 212 has a higher coefficient of thermal expansion than the material of the low expansion layer 211 .
- the bimetal 200 also has a central portion 221 , an outer peripheral portion 222 surrounding the central portion, and a boundary 223 between the central portion 221 and the outer peripheral portion 222 .
- the bimetal 200 has a convex shape with a protruding central portion 221 when viewed from above, and a concave shape with a depressed central portion 221 when viewed from below. It can also be said that the bimetal 200 is shaped like a rimmed dish.
- An angle ⁇ 2 formed between the central portion 221 and the outer peripheral portion 222 is an obtuse angle.
- the cross-sectional structure of the bimetal 200 is a composite curved line formed by combining a plurality of curved lines.
- the cross-sectional structure of the central portion 221 is curved downwardly, and the cross-sectional structure of both outer peripheral portions 222 on both sides of the central portion 221 is also curved downwardly.
- the radii of curvature of the respective curves in the central portion 221 and both outer peripheral portions 222 may be the same or different.
- the central portion 221 is circular, and the outer peripheral portion 222 is a square with rounded corners.
- the boundary 223 is on the circumference of concentric circles having a diameter length L22 that is 1% to 50% of the diameter length L21 of the circumscribed circle 231 that circumscribes the outer peripheral portion 222 .
- the length L22 of the diameter of this concentric circle is smaller than the width of the rounded square.
- a Ni--Fe alloy can be used for the low expansion layer 211
- a Cu--Ni--Mn alloy can be used for the high expansion layer 212.
- the length, width, corner shape, and plate thickness of the rounded square are arbitrarily set according to the target inversion temperature.
- the bimetal 200 after inversion has a concave shape in which the central portion 221 is recessed, and when viewed from below, it has a convex shape in which the central portion 221 protrudes.
- the shape after inversion is a composite curve formed by combining multiple curves.
- a boundary 223 between the central portion 221 and the outer peripheral portion 222 does not change before and after the inversion.
- the cross-sectional structure of the central portion 221 is curved downwardly, and the cross-sectional structure of both outer peripheral portions 222 on both sides of the central portion 221 is also curved downwardly.
- the radius of curvature of each curve may be the same or different.
- the angle ⁇ 2 formed by the central portion 221 and the outer peripheral portion 222 is an obtuse angle larger than the angle ⁇ 2.
- the angle ⁇ 2 is larger than the angle ⁇ 2, and the central portion 221 and the both outer peripheral portions 222 are each curved downwards, which is the same before and after the reversal. is also possible. Furthermore, as shown in FIG. 9, since the central portion 221 and both outer peripheral portions 222 are curved in the same direction (inward) (downwardly convex curved shape), an extremely high operating temperature can be set. It becomes possible. Then, when the temperature of the bimetal drops to a predetermined temperature (recovery temperature) or less, the bimetal reverses by snap action and returns from the shape shown in FIG. 10 to the shape shown in FIG. This return temperature is a temperature lower than the operating temperature.
- a predetermined temperature recovery temperature
- the boundary between one curve and another curve may be rounded or angular.
- the characteristics of the cross section of a straight line parallel to the longitudinal direction of the bimetal and passing through the center of the circumscribed circle have been described, similar characteristics apply to a cross section of an arbitrary straight line passing through the center.
- FIG. 9 has been described as the shape at room temperature after being formed by a plurality of stages of pressing using a punch and a die.
- bimetals that have been formed by pressing and then heat-treated have similar characteristics with respect to their shape at room temperature.
- the method for manufacturing the thermally responsive element 200 according to this embodiment is substantially the same as the method for manufacturing the thermally responsive element 100 according to the first embodiment. However, in the second step of the method of manufacturing the thermal responsive element 100, the bimetal material is pressed from the low expansion layer side, but in the second step of the method of manufacturing the thermal responsive element 200, the bimetal material is pressed from the high expansion layer side. pressed.
- FIG. 11A shows the first step of pressing the bimetal material 200a after cutting. The bimetal material 200a after cutting is placed on a die D having a flat surface. At this time, the bimetal material 200a is arranged so that the high expansion layer 212 is on the punch P1 side and the low expansion layer 211 is on the die D side.
- FIG. 11B shows the second step (final pressing step) of further pressing the bimetal material 200b obtained in the first step.
- the bimetal material 200b obtained by the first step is placed on a die D having a flat surface.
- the bimetal material 200b is arranged so that the high expansion layer 212 is on the punch P2 side and the low expansion layer 211 is on the die D side.
- the punch P2 having a protrusion formed on the end face is lowered to press the bimetal material 200b.
- the bimetal 200 shown in FIGS. 8 and 9 is obtained.
- the first step when the cut bimetal material 200a is placed on the die D, the low expansion layer 211 is placed on the punch P1 side and the high expansion layer 212 is placed on the die D side.
- This first step yields a bimetallic material 200c (FIG. 11B).
- the bimetal material 100c is placed and pressed so that the high expansion layer 212 is on the punch P2 side and the low expansion layer 211 is on the die D side, as in FIG. 11B.
- the punches P1 and P2 are made of metal, such as alloy tool steel, and the die D is made of an elastic material.
- the processed bimetal is subjected to heat treatment at a temperature of 100° C. to 500° C. for, for example, 1 hour.
- the bimetal material composition, plate thickness, temperature
- the shape after cutting the pressing force (force, time, temperature) in the first step and the second step
- the punch P1 The end face shape, the end face shape of the punch P2 (diameter lengths L13 and L14, protrusion amount H), and the material of the die are each appropriately selected.
- an operating temperature higher than room temperature and the return temperature can be set freely.
- a relatively small differential of around 10 degrees The operating temperature, return temperature, and differential can also be adjusted by changing the shape of the end face of the punch P1 in the first step.
- the differential adjustment effect is small, and if it exceeds 50% of the length L21 of the diameter, the bimetal snaps. It is difficult to flip by action, and even if it is flipped, the height after flipping is considered to be low. In other words, it is considered unfavorable for use in temperature switches and the like (cannot be effectively used for opening and closing electrical contacts).
- FIG. 13A to 13C are plan views of bimetals having different external shapes from the bimetals according to the first and second embodiments.
- the bimetal 300 has a circular shape in plan view and has a circular central portion 321 and an outer peripheral portion 322 .
- the diameter length L2 of the central portion 321 is 1% to 50% of the diameter length L1 of the bimetal 300 .
- the bimetal 400 has an elliptical shape in plan view, and has a circular central portion 421 and an outer peripheral portion 422 .
- the length L2 of the diameter of the central portion 421 is 1% to 50% of the length L1 of the diameter of the circumscribed circle 431 that circumscribes the outer peripheral portion of the bimetal 400 .
- the bimetal 500 has a diamond shape in plan view and has a circular central portion 521 and an outer peripheral portion 522 .
- the length L2 of the diameter of the central portion 521 is 1% to 50% of the length L1 of the diameter of the circumscribed circle 531 that circumscribes the outer periphery of the bimetal 500 .
- the cross-sectional shapes of bimetals 300, 400 and 500 are similar to the cross-sectional shape of bimetal 100 or 200. FIG. Such bimetals 300, 400 and 500 also provide the same actions and effects as described above.
- [Fourth embodiment] 14A to 14C are plan views of bimetals having a central shape different from that of the bimetals according to the first and second embodiments.
- the bimetal 600 has a square shape in plan view, and has an elliptical central portion 621 and an elliptical outer peripheral portion 622 .
- the long axis of central portion 621 extends in the width direction of bimetal 600 .
- the length L2 of the long axis is 1% to 50% of the length L1 of the diameter of the circumscribed circle 631 that circumscribes the outer periphery of the bimetal 600 .
- the center of the central portion 621 is at the center of the circumscribed circle 631 . As shown in FIG.
- the bimetal 700 has a square shape in plan view, and has an elliptical central portion 721 and an elliptical outer peripheral portion 722 .
- the longitudinal axis of central portion 721 extends along the length of bimetal 600 .
- the length L2 of the long axis is 1% to 50% of the length L1 of the diameter of the circumscribed circle 731 that circumscribes the outer periphery of the bimetal 700 .
- the center of the central portion 721 is at the center of the circumscribed circle 731 .
- the bimetal 800 has a square shape in plan view and has a central portion 821 and an outer peripheral portion 822 .
- the central portion 821 is shaped like a peanut (constricted in the middle and swollen on both sides), and the longitudinal direction of the central portion 821 is parallel to the longitudinal direction of the bimetal 800 .
- the length L2 of the central portion 821 is 1% to 50% of the length L1 of the diameter of the circumscribed circle 831 that circumscribes the outer periphery of the bimetal 800 .
- the center of the central portion 821 is at the center of the circumscribed circle 831 .
- the shape of the protruding portion X of the punch P2 can be elliptical or peanut-shaped.
- the cross-sectional shapes of bimetals 600, 700 and 800 are similar to the cross-sectional shape of bimetal 100 or 200.
- FIG. Such bimetals 600, 700 and 800 also provide the same actions and effects as described above.
- By setting the major axis of the elliptical shape or peanut shape at the center in the length direction or width direction of the bimetal it is possible to adjust the differential and change the reversal height when the bimetal is reversed.
- the major axis of the elliptical shape or peanut shape By setting the major axis of the elliptical shape or peanut shape at the center in the width direction of the bimetal, the height of the bimetal after reversal becomes greater than when the bimetal is set in the length direction of the outer shape of the bimetal.
- the bimetal 150 is shown in FIG. This bimetal 150 is obtained by providing a hole portion 151 in the central portion 121 of the bimetal 100 according to the first embodiment.
- a hole may be provided in the central portion 221 of the bimetal 200 according to the second embodiment.
- the hole can be used for positioning and fixing the bimetal when the bimetal is incorporated into a temperature switch or the like.
- the hole is not limited to circular and may be oval (not shown). However, it is preferable that the hole fits inside the boundary 123 between the central portion 121 and the outer peripheral portion 122 and that the center of the hole is the same as the center of the circumscribed circle 131 .
- the hole may be formed before the pressing process, in the middle of the pressing process (between the first process and the second process), or after the final step. With such a bimetal, the same actions and effects as described above can be obtained.
- the first embodiment and the second embodiment are appropriately changed by combining the outer shape of the bimetal, the shape of the central part, and the hole described in the third to fifth embodiments.
- the first step is performed after the bimetallic material is cut, but the pressing process of the first step may be performed simultaneously with the cutting of the bimetallic material.
- a progressive press can also be used to carry out the steps of drilling, contouring, pressing, and cutting the bimetal.
- the operating temperature and recovery temperature can be adjusted by the temperature and time of the heat treatment of the bimetal after pressing. It is possible to increase the operating and recovery temperatures by increasing the temperature and time of the heat treatment.
- the temperature at which the shape is reversed to the shape shown in FIG. 3 or from the shape shown in FIG. 10 to the shape shown in FIG. 9 is defined as the return temperature.
- the operating temperature was increased at a rate of 1° C./1 minute, and the return temperature was decreased at a rate of 1° C./1 minute.
- Example 1 (corresponding to the first embodiment) A bimetal having a plate thickness of 0.15 mm (a low expansion layer is a Ni--Fe alloy and a high expansion layer is a Cu--Ni--Mn alloy) was cut into rounded squares as shown in FIG.
- the outer shape was 14 mm ⁇ 10 mm, and the four corners were curved with a radius of curvature of 3 mm.
- the diameter of the circumscribed circle of this bimetal is 14.9 mm.
- this bimetal was placed on a die having a flat surface, and a punch whose tip had a radius of curvature of 24 mm was lowered to press the bimetal with a force of about 100 kgf for about 1 second.
- the low expansion layer of the bimetal was on the punch side and the high expansion layer was on the die side, or the high expansion layer was on the punch side and the low expansion layer was on the die side.
- the bimetal formed in the first step was placed on a flat die, and a punch having a convex portion was lowered to press the bimetal.
- the low-expansion layer of the bimetal was on the punch side, and the high-expansion layer was on the die side.
- the shape of the convex portion is the same as the shape shown in FIG.
- the length L14 of the diameter of Y was set to 15 mm.
- the diameter length L13 (5 mm) is about 34% of the 14.9 mm diameter of the circumscribed circle. Pressing was performed for about 1 second, and heat treatment was performed at 200° C. for 1 hour after pressing.
- Table 1 the results of experiments conducted while changing the pressure in the second step are shown as Examples 1-1 to 1-5.
- the operating temperature and recovery temperature were below room temperature, and as shown in Examples 1-1 to 1-4, the operating temperature and recovery temperature decreased as the pressure increased, and the operating temperature was the lowest. has reached -21.4°C, and the recovery temperature has reached -32.3°C. Under any conditions, the differential can be narrowed to the order of 10 degrees.
- Example 2 (corresponding to the first embodiment)
- the second step was carried out under the same conditions as in Example 1, except that the length L13 of the diameter of the convex portion of the punch used in the second step was set to 1.2 mm, 3 mm, or 6.4 mm, and the pressure was changed.
- the diameter length L13 of 1.2 mm, 3 mm, and 6.4 mm is about 8%, about 20%, and about 43% of the 14.9 mm diameter of the circumscribed circle.
- Table 1 shows the results as Examples 2-1 to 2-5.
- the temperature characteristics can be changed by the pressure of the punch in the second step and the length L13 of the diameter of the projection.
- a differential of less than 10 deg can be set by using a punch having protrusions with a diameter of 1.2 mm, 3 mm, or 6.4 mm.
- Example 3 (corresponding to the fifth embodiment) A bimetal material having a hole with a diameter of 2 mm was prepared, and the same experiment as in Example 1 was conducted. Even if a perforated bimetal is used, it is possible to fabricate a bimetal having cryogenic temperature characteristics and a narrow differential on the order of 10 degrees.
- Example 4 (corresponding to the third embodiment)
- the bimetal had a circular outer shape as shown in FIG. 13A and a diameter of 13 mm.
- Table 1 (Example 4) also shows the results of an experiment conducted under the same conditions as in Example 1 except for the shape of the bimetal. Even if the outer shape of the bimetal is circular, it is possible to manufacture a bimetal that has cryogenic temperature characteristics and a differential of less than 10 degrees.
- the length L13 of the diameter of the end surface of the protruding portion X of the punch in the second step is 5 mm, which is about 38% of the diameter of the bimetal, which is 13 mm.
- Example 5 (corresponding to the second embodiment) A bimetallic material having a plate thickness of 0.15 mm (a Ni--Fe alloy for the low expansion layer and a Cu--Ni--Mn alloy for the high expansion layer) was cut into a square with rounded corners as shown in FIG.
- the outer shape was 14 mm ⁇ 10 mm, and the four corners were curved with a radius of curvature of 3 mm.
- the diameter of the circumscribed circle of this bimetal is 14.9 mm.
- this bimetallic material was placed on a die having a flat surface, and a punch whose tip surface had a radius of curvature of 24 mm was lowered to press the bimetallic material with a force of approximately 100 kgf for approximately 1 second. At this time, the high expansion layer of the bimetal was on the punch side, and the low expansion layer was on the die side.
- a second step final pressing step
- the bimetal formed in the first step was placed on a flat die, and a punch having a projecting portion was lowered to press the bimetal. At this time, the high expansion layer of the bimetal was on the punch side, and the low expansion layer was on the die side.
- the shape of the projecting portion is the same as the shape shown in FIG.
- the length L14 of the diameter of the surface Y was set to 15 mm.
- the diameter length L13 (5 mm) is about 34% of the circumscribed circle diameter of 14.9 mm.
- Pressing was performed for about 1 second, and heat treatment was performed at 200° C. for 1 hour after pressing.
- Table 1 shows the results of experiments conducted by changing the pressure in the second step as Examples 5-1 to 5-3. As shown in the results, the operating temperature and recovery temperature were above room temperature, and the operating temperature and recovery temperature increased with the pressing of the punch in the second step, and a differential of less than 10 deg was obtained.
- Example 1 The second step was carried out under the same conditions as in Example 1, except that the length L13 of the diameter of the convex portion of the punch used in the second step was set to 7.6 mm, and the pressure was changed.
- the diameter length L13 (7.6 mm) is about 51% of the circumscribed circle diameter of 14.9 mm.
- Table 1 shows the results as Comparative Example 1.
- the bimetal manufactured under this condition did not turn over by snap action, and the turning temperature could not be measured with the bimetal temperature inspection device. From this, it can be seen that if the convex portion of the punch (that is, the boundary 123 of the bimetal) exceeds 50% of the diameter of the circumscribed circle, it will not be reversed by the snap action.
- Comparative Examples 2 and 3 As the punch used in the second step, the same punch used in the first step and having a tip end with a radius of curvature of 24 mm was used. In Comparative Example 2, in the first step, the low-expansion layer of the bimetal is on the punch side and the high-expansion layer is on the die side, and in the second step, the high-expansion layer of the bimetal is on the punch side and the low-expansion layer is on the die side.
- Comparative Example 3 in the first step, the high expansion layer of the bimetal is on the punch side and the low expansion layer is on the die side, and in the second step, the low expansion layer of the bimetal is on the punch side and the high expansion layer is on the die side.
- Table 1 (Comparative Examples 2 and 3) also shows the results of experiments conducted under the same conditions as in Example 1 except that the pressure in the second step was changed. Even when the direction of pressing the bimetal was changed, the operating temperature and the return temperature did not change much, and the differential exceeded 35 degrees.
- the cross-sectional structure at room temperature where these bimetals are reversed below the return temperature is a curved line with the low expansion layer convex upward as in FIG. Absent.
- the inverted cross-sectional structure above the operating temperature is also a single curve (not shown), not a compound curve.
- a bimetal having a cross-sectional structure consisting of a single curve lacks the degree of freedom in setting the operating temperature, return temperature, and differential, and cannot set a relatively narrow differential of around 10 degrees.
- thermoly responsive elements other than bimetals, such as shape memory alloys (100° C. or less) and trimetals.
- a plate-shaped thermally responsive element whose shape changes with changes in temperature
- the cross section of the thermal response element at room temperature is a compound curve formed by combining a plurality of curves, and the cross section of the central portion of the thermal response element and the outer peripheral portion surrounding the central portion have different curved cross sections
- the shape of the thermally responsive element changes
- a cross-section of the thermally responsive element after the shape change has a compound curved shape formed by combining a plurality of curved lines, and a central portion of the thermally responsive element and an outer peripheral portion surrounding the central portion have different curved cross-sections.
- a boundary between the central portion and the outer peripheral portion is the same before and after the shape change of the thermal responsive element;
- Thermally responsive element is a bimetal comprising a first metal layer and a second metal layer below the first metal layer and having a higher coefficient of thermal expansion than the first metal layer;
- the predetermined temperature is a temperature below the room temperature, At room temperature, the thermally responsive element has a shape in which the central portion protrudes downward and the entire shape is downwardly convex, The thermally responsive element after the shape change has an upwardly convex shape as a whole with the central portion protruding upward.
- the thermally responsive element according to appendix 1.
- the thermally responsive element is a bimetal comprising a first metal layer and a second metal layer below the first metal layer and having a higher coefficient of thermal expansion than the first metal layer;
- the predetermined temperature is a temperature above room temperature, At room temperature, the thermally responsive element has an upwardly convex shape as a whole with the central portion protruding upwards,
- the thermally responsive element after the shape change has a shape in which the central portion protrudes downward and the whole is downwardly convex.
- the thermally responsive element according to appendix 1.
- the thermally responsive element has a rounded square shape in a plan view, 4.
- the thermally responsive element has a circular shape in plan view, 4.
- Appendix 6 A method for manufacturing a thermally responsive element according to any one of Appendices 1 to 5, A step of molding the material of the thermally responsive element by a multi-stage pressing process using a press machine; In the final step of pressing in the plurality of steps of pressing, a metal punch having a protruding central portion and a die made of an elastic material are used. Method.
- Appendix 7 A method for manufacturing a thermally responsive element according to any one of Appendices 1 to 5, A method comprising the step of sandwiching the material of the thermally responsive element between upper and lower metal molds and pressing the material.
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Abstract
Description
また、特許文献2には、反転・再反転の温度差(ディファレンシャル)の小さいバイメタルディスクが記載されている。このバイメタルディスクは、平板のバイメタルディスクを中心から一定距離の位置で全周にわたり折り曲げ、断面形状を中心部も周辺部も直線とし、縁付皿状に形成される。低膨張側に折り曲げることで室温より低い温度で動作することもできるとされている。
さらに、特許文献3には、張り出し加工された領域の少なくとも一面は凹凸を付設されて表面積を大になされていることを特徴とするディスク型バイメタルが記載されている。このディスク型バイメタルは、反転復帰温度が低く、またそれらの温度差が小さいとされている。
[構成]
図1は、本実施形態に係る熱応動素子であるバイメタル100の平面図である。図2は、図1のA-A’線断面図である。両図とも、パンチとダイを用いて複数段の押圧加工で成形されたバイメタル100の室温での形状を示す。
図3において、中心部121の断面構造は上に凸の曲線状であり、中心部121の両側にある両外周部122の断面構造もそれぞれ上に凸の曲線状である。それぞれの曲線の曲率半径は、同じでも異なっていてもよい。
図3において中心部121と外周部122とのなす角β1は角α1よりも大きい鈍角である。
角β1は角α1よりも大きく、かつ中心部121及び両外周部122のそれぞれが上に凸の曲線状であることは反転前後で変わりがないという特徴により、10deg前後の比較的小さいディファレンシャルの設定も可能になる。更に図2に示したように、中心部121と両外周部122とが、同一方向(内側)に向かって湾曲する形状(上に凸の曲線状)であるため、極端に低い復帰温度設定も可能となる。
そして、バイメタルの温度が上昇し、室温よりも低い所定の温度(動作温度)以上になると、バイメタルがスナップアクションで反転して、図3に示した形状から図2に示した形状へと戻る。この動作温度は、上記復帰温度よりも高い温度である。
複合曲線においては、ある曲線と別の曲線との境界部が丸みを帯びていてもよいし、角張っていてもよい。
なお、前記断面はバイメタルの長手方向に平行で外接円の中心を通る直線における断面の特徴を説明したが、中心を通る任意の直線の断面でも同様の特徴である。
また、図2はパンチとダイを用いて複数段の押圧加工で成形された後の室温での形状と説明した。しかし、押圧加工により成形した後に熱処理を行ったバイメタルも、室温での形状に関して同様の特徴を有する。
バイメタル100の製造方法は、熱膨張率が異なる2種の金属層で構成されるバイメタル素材を任意の形状に切断するステップと、切断後のバイメタル素材を、プレス機械を用いた複数段の押圧加工によりバイメタル100へと成形するステップとを含む。前記複数段の押圧加工は、バイメタル素材とパンチとダイを含む金型とが室温と同程度の温度(18℃以上38℃以下)に維持された状態で行われる。ただし、それらを冷却や加熱したうえで複数段の押圧加工を行ってもよい。パンチは金属製で合金工具鋼などが用いられ、ダイは弾性材料で構成される。
図4Bに、第1の工程により成形したバイメタル素材100bを更に押圧する第2の工程(最終段の押圧工程)を示す。第1の工程により得られたバイメタル素材100bを、平面を有するダイD上に配置する。このとき、低膨張層111が金属製のパンチP2側、高膨張層112がダイD側となるようにバイメタル素材100bを配置する。そして、端面に突出部が形成されたパンチP2を下げてバイメタル素材100bを押圧する。このような第2の工程により、図1及び図2に示したバイメタル100が得られる。
そして、図5Bに示す第2の工程では、図4Bと同様に、低膨張層111がパンチP2側、高膨張層112がダイD側となるようにバイメタル素材100cを配置して押圧加工を行う。
なお、端面Yは円形に限られず、楕円形あるいは四角形(不図示)とすることもできる。
なお、図7に、金属製パンチと弾性材料で構成されたダイとによる製造方法を示したが、これに限られない。バイメタル素材の外形を加工した後に、目的とするバイメタルの曲線形状に合った曲線形状を有する金属製の上下型でバイメタル素材を挟み込んで押圧加工してもよい。押圧加工後のバイメタル素材は、50℃~300℃の温度で例えば1時間の熱処理が施される。
前記の製造方法において、バイメタルの素材(組成、板厚、温度)と、切断後の形状と、第1の工程と第2の工程のそれぞれの押圧(力、時間、温度)と、パンチP1の端面形状と、パンチP2の端面形状(直径の長さL13及びL14、突出量H)と、ダイの材質とは、それぞれ適宜選択される。これにより、室温より低い動作温度の設定が可能で、復帰温度を自由に設定できる。10deg前後の比較的小さいディファレンシャルの設定も可能となる。第1の工程のパンチP1の端面形状を変更することによっても、動作温度、復帰温度、ディファレンシャルを調整することができる。
なお、中心部121の直径の長さL12が、外接円131の直径の長さL11の1%未満の場合、ディファレンシャルの調整効果が少なく、直径の長さL11の50%を超えるとバイメタルがスナップアクションで反転しにくく、また、反転したとしても反転後の高さが低いと考えられる。つまり、温度スイッチなどへの利用において好ましくない(電気接点の開閉に有効に利用できない)と考えられる。
[構成]
図8は、本実施形態に係る熱応動素子であるバイメタル200の平面図である。図9は、図8のB-B’線断面図である。両図とも、パンチとダイを用いて複数段の押圧加工で成形されたバイメタル200の室温での形状を示す。
図10において、中心部221の断面構造は下に凸の曲線状であり、中心部221の両側にある両外周部222の断面構造もそれぞれ下に凸の曲線状である。それぞれの曲線の曲率半径は、同じでも異なっていてもよい。
図10において中心部221と外周部222とのなす角β2は角α2よりも大きい鈍角である。
角β2は角α2よりも大きく、かつ中心部221及び両外周部222のそれぞれが下に凸の曲線状であることは反転前後で変わりがないという特徴により、10deg前後の比較的小さいディファレンシャルの設定も可能になる。更に図9に示したように、中心部221と両外周部222とが、同一方向(内側)に向かって湾曲する形状(下に凸の曲線状)であるため、極端に高い動作温度設定も可能となる。
そして、バイメタルの温度が低下し、所定の温度(復帰温度)以下になると、バイメタルがスナップアクションで反転して、図10に示した形状から図9に示した形状へと戻る。この復帰温度は、上記動作温度よりも低い温度である。
複合曲線においては、ある曲線と別の曲線との境界部が丸みを帯びていてもよいし、角張っていてもよい。
なお、前記断面はバイメタルの長手方向に平行で外接円の中心を通る直線における断面の特徴を説明したが、中心を通る任意の直線の断面でも同様の特徴である。
また、図9はパンチとダイを用いて複数段の押圧加工で成形された後の室温での形状と説明した。しかし、押圧加工により成形した後に熱処理を行ったバイメタルも、室温での形状に関して同様の特徴を有する。
本実施形態に係る熱応動素子200の製造方法は、第1の実施形態に係る熱応動素子100の製造方法とほぼ同じである。ただし、熱応動素子100の製造方法の第2工程において、バイメタル素材が低膨張層側から押圧されるが、熱応動素子200の製造方法の第2工程においては、バイメタル素材が高膨張層側から押圧される。
図11Aに、切断後のバイメタル素材200aを押圧加工する第1の工程を示す。切断後のバイメタル素材200aを、平面を有するダイD上に配置する。このとき、高膨張層212がパンチP1側、低膨張層211がダイD側となるように、バイメタル素材200aを配置する。そして、端面が凸曲面のパンチP1を下げてバイメタル素材200aを押圧する。このような第1の工程によりバイメタル素材200b(図11B)が得られる。
図11Bに、第1の工程により得られたバイメタル素材200bを更に押圧する第2の工程(最終段の押圧工程)を示す。第1の工程により得られたバイメタル素材200bを、平面を有するダイD上に配置する。このとき、高膨張層212がパンチP2側、低膨張層211がダイD側となるようにバイメタル素材200bを配置する。そして、端面に突出部が形成されたパンチP2を下げてバイメタル素材200bを押圧する。このような第2の工程により、図8及び図9に示したバイメタル200が得られる。
そして、図12Bに示す第2の工程では、図11Bと同様に、高膨張層212がパンチP2側、低膨張層211がダイDとなるようにバイメタル素材100cを配置して押圧加工を行う。
前記の製造方法において、バイメタルの素材(組成、板厚、温度)と、切断後の形状と、第1の工程と第2の工程のそれぞれの押圧(力、時間、温度)と、パンチP1の端面形状と、パンチP2の端面形状(直径の長さL13及びL14、突出量H)と、ダイの材質とは、それぞれ適宜選択される。これにより、室温より高い動作温度の設定が可能で、復帰温度を自由に設定できる。10deg前後の比較的小さいディファレンシャルの設定も可能となる。第1の工程のパンチP1の端面形状を変更することによっても、動作温度、復帰温度、ディファレンシャルを調整することができる。
なお、中心部221の直径の長さL22が、外接円231の直径の長さL21の1%未満の場合、ディファレンシャルの調整効果が少なく、直径の長さL21の50%を超えるとバイメタルがスナップアクションで反転しにくく、また、反転したとしても反転後の高さが低いと考えられる。つまり、温度スイッチなどへの利用において好ましくない(電気接点の開閉に有効に利用できない)と考えられる。
図13A~図13Cは、第1及び第2の実施形態に係るバイメタルとは外形が異なるバイメタルの平面図である。
図13Aに示すように、バイメタル300は平面視円形状であり、円形状の中心部321と外周部322とを有する。中心部321の直径の長さL2は、バイメタル300の直径の長さL1の1%~50%である。
図13Bに示すように、バイメタル400は平面視楕円形状であり、円形状の中心部421と外周部422とを有する。中心部421の直径の長さL2は、バイメタル400の外周部に外接する外接円431の直径の長さL1の1%~50%である。
図13Cに示すように、バイメタル500は平面視菱形状であり、円形状の中心部521と外周部522とを有する。中心部521の直径の長さL2は、バイメタル500の外周部に外接する外接円531の直径の長さL1の1%~50%である。
バイメタル300、400及び500の断面形状は、バイメタル100又は200の断面形状と同様である。このようなバイメタル300、400及び500によっても上記と同様の作用、効果が得られる。
図14A~図14Cは、第1及び第2の実施形態に係るバイメタルとは中心部の形状が異なるバイメタルの平面図である。
図14Aに示すように、バイメタル600は平面視四角形状であり、楕円形状の中心部621と外周部622とを有する。中心部621の長軸はバイメタル600の幅方向に延びている。長軸の長さL2は、バイメタル600の外周部に外接する外接円631の直径の長さL1の1%~50%である。中心部621の中心は外接円631の中心にある。
図14Bに示すように、バイメタル700は平面視四角形状であり、楕円形状の中心部721と外周部722とを有する。中心部721の長軸はバイメタル600の長さ方向に延びている。長軸の長さL2は、バイメタル700の外周部に外接する外接円731の直径の長さL1の1%~50%である。中心部721の中心は外接円731の中心にある。
図14Cに示すように、バイメタル800は平面視四角形状であり、中心部821と外周部822とを有する。中心部821はピーナッツ状(中間がくびれて両隣がふくらんだ形状)であり、中心部821の長手方向は、バイメタル800の長さ方向と平行である。中心部821の長さL2は、バイメタル800の外周部に外接する外接円831の直径の長さL1の1%~50%である。中心部821の中心は外接円831の中心にある。
バイメタル600、700及び800を製造するにあたり、パンチP2の突出部Xの形状を楕円形状あるいはピーナッツ形状とすることができる。バイメタル600、700及び800の断面形状は、バイメタル100又は200の断面形状と同様である。このようなバイメタル600、700及び800によっても上記と同様の作用、効果が得られる。
中心部の楕円形状あるいはピーナッツ形状の長軸を、バイメタルの外形の長さ方向又は幅方向とすることにより、ディファレンシャルの調整や、バイメタルが反転した時の反転高さを変化させることができる。中心部の楕円形状あるいはピーナッツ形状の長軸をバイメタルの外形の幅方向とすることで、バイメタルの外形の長さ方向とする場合に比べて、反転後のバイメタルの高さが大きくなる。反転後のバイメタルの高さが大きくなることで、例えば温度スイッチに利用するときに、可動接点が設けられた可動板をバイメタルにより押し上げる高さを増加させて、遮断電流容量を増加させることができる。この様に、中心部の形状が円形ではない形状とすることによって、多彩なバイメタル反転特性を創出することが可能となる。
図15にバイメタル150を示す。このバイメタル150は、第1の実施形態に係るバイメタル100の中心部121に孔部151を設けたものである。なお、第2の実施形態に係るバイメタル200の中心部221に孔部を設けてもよい。
バイメタルを温度スイッチなどに組み入れる際の、バイメタルの位置決めや固定に上記孔部を利用することができる。孔部は円形に限られず楕円形(不図示)でもよい。ただし、中心部121と外周部122との境界123の内側に孔部が収まり、孔部の中心が外接円131の中心と同一であることが好ましい。
孔部の形成は、押圧工程前に行ってもよいし、押圧工程の中間(第1の工程と第2の工程の間)あるいは最終段の工程の後に行ってもよい。
このようなバイメタルによっても上記と同様の作用、効果が得られる。
実施の形態1、2では、バイメタル素材を切断した後、第1の工程を実施するとしたが、バイメタルの切断と同時に第1の工程の押圧加工を行ってもよい。また、順送プレスを使用してバイメタルの孔あけ、外形抜き、押圧、切断の工程を実施することもできる。
押圧加工後のバイメタルの熱処理の温度と時間により、動作温度と復帰温度を調整することができる。熱処理の温度と時間の増加により動作温度と復帰温度を高くすることが可能である。
次に、表1を参照して、上記第1から第3の実施形態及び第5の実施形態による効果を確認するために行った実験とその結果を説明する。なお、いずれの実験でも、プレス機を使用し、パンチの素材は合金工具鋼、ダイの素材として弾性材料であるウレタンを使用した。第1の工程と第2の工程における押圧をロードセル(荷重変換器)を使用して測定した。動作温度と復帰温度は、空気循環方式のバイメタル温度検査装置で槽内の温度を変化させて、バイメタルの反転の衝撃を検出する方法で測定した。先に述べたように、温度の上昇に伴い図3の形状から図2の形状、または、図9の形状から図10の形状に反転する温度を動作温度とし、温度の下降に伴い図2の形状から図3の形状、または、図10の形状から図9の形状に反転する温度を復帰温度とする。実験では、動作温度は1℃/1分の上昇速度、復帰温度は1℃/1分の下降速度で槽内温度を変化させて測定した。
0.15mmの板厚を有するバイメタル(低膨張層はNi-Fe系合金、高膨張層はCu-Ni-Mn系合金)を、図1に示した角丸四角形に切断した。外形は、14mm×10mmであり、4つの角部は曲率半径3mmの曲線状とした。このバイメタルの外接円の直径は14.9mmである。バイメタルとパンチとダイを含む金型とは、室温と同程度の温度で維持した。
第1の工程として、このバイメタルを、平面を有するダイ上に配置し、先端が曲率半径24mmのパンチを下げてバイメタルを約100kgfの力で約1秒間押圧した。このとき、バイメタルの低膨張層がパンチ側、高膨張層がダイ側となるように、又は、高膨張層がパンチ側、低膨張層がダイ側となるようにした。
次に、第2の工程(最終段の押圧工程)として、第1の工程で成形されたバイメタルを、平面を有するダイ上に配置し、凸部を有するパンチを下げてバイメタルを押圧した。このとき、バイメタルの低膨張層がパンチ側、高膨張層がダイ側となるようにした。凸部の形状は図6に示した形状と同様で、突出部Xの端面と端面Yは平面とし、突出部Xの端面の直径の長さL13を5mm、突出量Hを0.3mm、面Yの直径の長さL14を15mmとした。直径の長さL13(5mm)は、前記外接円の直径14.9mmの約34%である。押圧は約1秒間とし、押圧加工後に200℃で1時間の熱処理を行った。
表1においては、第2の工程の押圧を変化させて実験を行った結果を実施例1-1~1-5として示す。表1に示す様に、動作温度と復帰温度は室温以下であり、実施例1-1~1-4で示される様に押圧の増加に伴い動作温度と復帰温度は低下し、最低で動作温度は-21.4℃、復帰温度は-32.3℃に到達している。いずれの条件でも、ディファレンシャルは10deg台と狭くすることができている。
第2の工程に用いるパンチの凸部の直径の長さL13を1.2mm、3mm、または6.4mmとし、押圧を変化させた以外は実施例1と同一の条件で実施した。直径の長さL13が、1.2mm、3mm、6.4mmは、前記外接円の直径14.9mmの約8%、約20%、約43%である。表1に実施例2-1~2-5として結果を示す。第2の工程のパンチの押圧と凸部の直径の長さL13により、温度特性を変化させることができている。この様に直径1.2mm、3mm、または6.4mmの凸部を有するパンチを使用することで、10deg未満のディファレンシャルを設定できる。
直径2mmの孔をあけたバイメタル素材を準備し、実施例1と同様の実験を行った結果を同じく表1に実施例3として示す。孔をあけたバイメタルを使用しても、極低温の温度特性をもち、10deg台の狭いディファレンシャルをもつバイメタルを製作することができている。
バイメタルの外形を図13Aに示した様な円形とし、直径を13mmとした。バイメタルの外形以外は実施例1と同じ条件で行った実験の結果を同じく表1(実施例4)に示す。バイメタルの外形を円形にしても、極低温の温度特性をもち、10deg未満のディファレンシャルをもつバイメタルを製作することができている。なお、第2の工程におけるパンチの突出部Xの端面の直径の長さL13は5mmであり、前記バイメタルの外形の直径13mmの約38%である。
0.15mmの板厚を有するバイメタル素材(低膨張層はNi-Fe系合金、高膨張層はCu-Ni-Mn系合金)を、図8に示した角丸四角形に切断した。その外形は、14mm×10mmであり、4つの角部は曲率半径3mmの曲線状とした。このバイメタルの外接円の直径は14.9mmである。バイメタルとパンチとダイを含む金型は、室温と同程度の温度で維持した。
第1の工程として、このバイメタル素材を、平面を有するダイ上に配置し、先端面が曲率半径24mmのパンチを下げてバイメタル素材を約100kgfの力で約1秒間押圧した。このとき、バイメタルの高膨張層がパンチ側、低膨張層がダイ側となるようにした。
次に、第2の工程(最終段の押圧工程)として、第1の工程で成形したバイメタルを、平面を有するダイ上に配置し、突出部を有するパンチを下げてバイメタルを押圧した。このとき、バイメタルの高膨張層がパンチ側、低膨張層がダイ側となるようにした。突出部の形状は図6に示した形状と同様であり、突出部Xの端面と端面Yは平面とし、突出部Xの端面の直径の長さL13を5mm、突出量Hを0.3mm、面Yの直径の長さL14を15mmとした。直径の長さL13(5mm)は、外接円の直径14.9mmの約34%である。押圧は約1秒間とし、押圧加工後に200℃で1時間の熱処理を行った。
表1に、第2の工程の押圧を変化せて実験を行った結果を実施例5-1~5-3として示す。結果に示される様に、動作温度と復帰温度は室温以上であり、第2の工程のパンチの押圧に伴い、動作温度及び復帰温度が増加し、10deg未満のディファレンシャルを得ることもできている。
第2の工程に用いるパンチの凸部の直径の長さL13を7.6mmとし、押圧を変化させた以外は実施例1と同一の条件で実施した。直径の長さL13(7.6mm)は、前記外接円の直径14.9mmの約51%である。表1に比較例1として結果を示す。この条件で製作したバイメタルはスナップアクションで反転せず、バイメタル温度検査装置で反転温度の計測ができなかった。このことからパンチの凸部(すなわちバイメタルの境界123)が前記外接円の直径の50%を超えるとスナップアクションで反転しないことがわかる。
第2の工程に用いるパンチを、第1の工程に用いるパンチと同一の先端が曲率半径24mmのパンチを使用した。比較例2では、第1の工程はバイメタルの低膨張層がパンチ側、高膨張層がダイ側となるようにし、第2の工程はバイメタルの高膨張層がパンチ側、低膨張層がダイ側となるようにした。比較例3では、第1の工程はバイメタルの高膨張層がパンチ側、低膨張層がダイ側となるようにし、第2の工程はバイメタルの低膨張層がパンチ側、高膨張層がダイ側となるようにした。これらと第2の工程の押圧を変化させた以外は実施例1と同一の条件で行った実験の結果を同じく表1(比較例2、3)に示す。
バイメタルを押圧する向きを変化させても動作温度と復帰温度はあまり変化せず、ディファレンシャルは35degを超えた。これらのバイメタルが復帰温度以下で反転した室温での断面構造は、図3と同様に低膨張層を上に凸の曲線状であるが、単一の曲線(不図示)であり、複合曲線ではない。また、動作温度以・BR>繧ナ反転した断面構造も単一の曲線(不図示)であり、複合曲線ではない。このような単一曲線からなる断面構造のバイメタルは、動作温度と復帰温度、ディファレンシャルの設定の自由度がなく、10deg前後の比較的狭いディファレンシャル設定ができない。
[付記1]
温度変化に伴い形状が変化する板状の熱応動素子であって、
室温における前記熱応動素子の断面が複数の曲線を組み合わせてなる複合曲線状であり、前記熱応動素子の中心部と前記中心部を取り囲む外周部とにおいて断面がそれぞれ別の曲線状であり、
室温の範囲外の所定温度になると前記熱応動素子の形状が変化し、
形状変化後の前記熱応動素子の断面が複数の曲線を組み合わせてなる複合曲線状であり、前記熱応動素子の中心部と前記中心部を取り囲む外周部とにおいて断面がそれぞれ別の曲線状であり、
前記中心部と前記外周部との境界は、前記熱応動素子の形状変化の前後で同一である、
熱応動素子。
[付記2]
前記熱応動素子が、第1の金属層と、前記第1の金属層の下にあり前記第1の金属層よりも熱膨張率が大きい第2の金属層とを備えたバイメタルであり、
前記所定温度が前記室温を下回る温度であり、
室温において前記熱応動素子は、前記中心部が下方に突出し全体として下に凸の形状であり、
形状変化後の前記熱応動素子は、前記中心部が上方に突出し全体として上に凸の形状である、
付記1に記載の熱応動素子。
[付記3]
前記熱応動素子が、第1の金属層と、前記第1の金属層の下にあり前記第1の金属層よりも熱膨張率が大きい第2の金属層とを備えたバイメタルであり、
前記所定温度が前記室温を上回る温度であり、
室温において前記熱応動素子は、前記中心部が上方に突出し全体として上に凸の形状であり、
形状変化後の前記熱応動素子は、前記中心部が下方に突出し全体として下に凸の形状である、
付記1に記載の熱応動素子。
[付記4]
前記熱応動素子が平面視で角丸四角形状であり、
前記境界が、前記角丸四角形に外接する外接円の直径の1%から50%の長さの直径を有する同心円の円周上にある、付記1~3のいずれか一項に記載の熱応動素子。
[付記5]
前記熱応動素子が平面視で円形状であり、
前記境界が、前記円形の直径の1%から50%の長さの直径を有する同心円の円周上にある、付記1~3のいずれか一項に記載の熱応動素子。
[付記6]
付記1~5のいずれか一項に記載の熱応動素子を製造する方法であって、
前記熱応動素子の素材を、プレス機械による複数段の押圧加工で成形する工程を含み、
前記複数段の押圧加工における最終段の押圧加工において、中央部が突出した形状の金属製パンチと、弾性材料で構成されるダイとが用いられる、
方法。
[付記7]
付記1~5のいずれか一項に記載の熱応動素子を製造する方法であって、
前記熱応動素子の素材を金属製の上下型で挟み込んで押圧加工する工程を含む方法。
111、211 低膨張層
112、212 高膨張層
121、221 中心部
122、222 外周部
123、223 境界
131、231 外接円
151 孔部
L1、L11、L21 長さ
L2、L12、L22 長さ
P1、P2 パンチ
D ダイ
Claims (7)
- 温度変化に伴い形状が変化する板状の熱応動素子であって、
室温における前記熱応動素子の断面が複数の曲線を組み合わせてなる複合曲線状であり、前記熱応動素子の中心部と前記中心部を取り囲む外周部とにおいて断面がそれぞれ別の曲線状であり、
室温の範囲外の所定温度になると前記熱応動素子の形状が変化し、
形状変化後の前記熱応動素子の断面が複数の曲線を組み合わせてなる複合曲線状であり、前記熱応動素子の中心部と前記中心部を取り囲む外周部とにおいて断面がそれぞれ別の曲線状であり、
前記中心部と前記外周部との境界は、前記熱応動素子の形状変化の前後で同一である、
熱応動素子。 - 前記熱応動素子が、第1の金属層と、前記第1の金属層の下にあり前記第1の金属層よりも熱膨張率が大きい第2の金属層とを備えたバイメタルであり、
前記所定温度が前記室温を下回る温度であり、
室温において前記熱応動素子は、前記中心部が下方に突出し全体として下に凸の形状であり、
形状変化後の前記熱応動素子は、前記中心部が上方に突出し全体として上に凸の形状である、
請求項1に記載の熱応動素子。 - 前記熱応動素子が、第1の金属層と、前記第1の金属層の下にあり前記第1の金属層よりも熱膨張率が大きい第2の金属層とを備えたバイメタルであり、
前記所定温度が前記室温を上回る温度であり、
室温において前記熱応動素子は、前記中心部が上方に突出し全体として上に凸の形状であり、
形状変化後の前記熱応動素子は、前記中心部が下方に突出し全体として下に凸の形状である、
請求項1に記載の熱応動素子。 - 前記熱応動素子が平面視で角丸四角形状であり、
前記境界が、前記角丸四角形に外接する外接円の直径の1%から50%の長さの直径を有する同心円の円周上にある、請求項1~3のいずれか一項に記載の熱応動素子。 - 前記熱応動素子が平面視で円形状であり、
前記境界が、前記円形の直径の1%から50%の長さの直径を有する同心円の円周上にある、請求項1~3のいずれか一項に記載の熱応動素子。 - 請求項1~3のいずれか一項に記載の熱応動素子を製造する方法であって、
前記熱応動素子の素材を、プレス機械による複数段の押圧加工で成形する工程を含み、
前記複数段の押圧加工における最終段の押圧加工において、中央部が突出した形状の金属製パンチと、弾性材料で構成されるダイとが用いられる、
方法。 - 請求項1~3のいずれか一項に記載の熱応動素子を製造する方法であって、
前記熱応動素子の素材を金属製の上下型で挟み込んで押圧加工する工程を含む方法。
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JPS5118069B1 (ja) * | 1970-10-16 | 1976-06-07 | ||
JPS58198788A (ja) * | 1982-05-17 | 1983-11-18 | 日本ジ−・ティ−株式会社 | バイメタルデイスク |
WO2020121584A1 (ja) * | 2018-12-12 | 2020-06-18 | ウチヤ・サーモスタット株式会社 | 温度スイッチ |
JP2020095888A (ja) * | 2018-12-14 | 2020-06-18 | ボーンズ株式会社 | 熱応動素子、ブレーカー、安全回路及び2次電池パック |
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JPS4810429B1 (ja) | 1968-07-04 | 1973-04-03 | ||
JPS6316285U (ja) | 1986-07-17 | 1988-02-03 |
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JPS5118069B1 (ja) * | 1970-10-16 | 1976-06-07 | ||
JPS58198788A (ja) * | 1982-05-17 | 1983-11-18 | 日本ジ−・ティ−株式会社 | バイメタルデイスク |
WO2020121584A1 (ja) * | 2018-12-12 | 2020-06-18 | ウチヤ・サーモスタット株式会社 | 温度スイッチ |
JP2020095888A (ja) * | 2018-12-14 | 2020-06-18 | ボーンズ株式会社 | 熱応動素子、ブレーカー、安全回路及び2次電池パック |
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